10 Nov 2023

DEPARTMENT OF FOOD AND AGRICULTURAL ENGINEERING

DESIGN AND SELECTION

OF MATERIAL HANDLING
AND STORAGE EQUIPMENT
ABEN 125 – DESIGN AND MANAGEMENT OF AB PROCESSING
SYSTEMS

Adapted from: RMMO ABEN125 Lectures

OBJECTIVES
•Be familiar with the different material
handling equipment
•Analyze the performance of equipment
•Calculate the power requirements of plant
equipment

1
 10 Nov 2023

Design and Selection of Plant

Equipment
•Introduction
•Design Considerations
•Storage of Solids
• Bins and Hoppers
• Volumetric and Gravimetric Feeders
•Conveying of Solids

Introduction
• Foods, fertilizers, and most products are finished as solid-
phase products.
• Solids are, in general, more difficult to process than gases or
liquids.
• The equipment used for processing solids consumes more
power (usually in the form of electricity) and is more likely to
suffer mechanical failure.
• Solids-handling plants can be prone to shutdowns due to
caking or plugging of equipment, or interruptions of solids flow
caused by bridging of poorly designed hoppers and feeders.

2
 10 Nov 2023

Design Considerations
A. Based on the Properties of Solid
Particles

1. Particle Size and Shape

2. Density and Porosity
3. Particle Strength and Hardness
4. Particle Chemical Properties

Design Considerations
B. Based on the Bulk and Flow Properties of
Particulate Materials

1. Particle Size Distribution

2. Voidage and Bulk Density
3. Cohesion
4. Flow Properties
5. Fluidization

3
 10 Nov 2023

Storage of Solids
• Storage bins are used for solids that must be
protected from the elements and for storing smaller
quantities of solids for process use.
• A bin is any vertical walled vessel used for storing
solids.
• conical or wedge-shaped hopper at the base
• flat-bottomed
• Silos – bins with height to diameter ratio > 1.5
• Bunkers - bins with height to diameter < 1.5

Storage of Solids

4
 10 Nov 2023

Storage of Solids
• Large bunkers and silos used for agricultural
products, cement, and bulk minerals typically
hold 50 to 1000 metric tons of solids and are
usually constructed from reinforced concrete.
• The design of large bins requires analysis of the
wall stresses caused during filling and discharge
of the solids.
• Large scale concrete silos are often used to store
material for days, weeks, or even months.

Flow Patterns in Bins and Hoppers

Three Main Types of Flow

1.Mass Flow
2.Funnel Flow
3.Expanded Flow

5
 10 Nov 2023

Mass Flow
• slip occurs between the solids and the wall
and all the particulate material is moving
downwards.
• no stagnant regions in the bin or hopper and
there is a reduced tendency for the particles to
segregate by particle size during flow.
• “first-in first-out,” as material from the top of
the bin does not channel to the exit.

Funnel Flow
•slip occurs within the solid at an angle
roughly equal to the angle of internal
friction if the solids have low cohesion.
•are usually more cost effective to
construct, costing between 20-30% less
than mass flow silos
•when the solids are cohesive, rat-holes,
bridges, or arches can occur.

6
 10 Nov 2023

Flow Patterns in Bins and Hoppers

Funnel Flow
• Flow is interrupted while the hopper is still
largely full, and level detection devices may no
longer function correctly.
• If a bridge or rat-hole in a fine powder
collapses suddenly, the void fraction increases
rapidly and uncontrollable flow through the
discharge known as flushing occurs.

7
 10 Nov 2023

Expanded Flow
• One method of avoiding the problems of funnel flow
is to use a steep-walled hopper at the base of a
funnel flow bin, to create a mass flow zone at the
base with a funnel flow zone above.
• The entry of the mass flow section is sized to be
large enough that a stable arch cannot form. The
resulting combination of funnel flow and mass flow
is known as expanded flow.

Flow Patterns in Bins and Hoppers

8
 10 Nov 2023

Flow of Solids from an Unregulated

Orifice
The mass flow rate of solids
from an open conical hopper or
flat-bottomed bin has been
shown to be constant and
independent of the vessel
diameter, D, or depth of solids,
H, as long as H > D (Brown and
Richards, 1959) and D > 2.5Do,
where Do is the diameter of the
opening at the base of the
vessel.

Flow of Solids from an Unregulated

Orifice
Most correlations for solids flow rate are derived from that of
Beverloo, Leniger, and van de Velde (1961):

The choice of constant k depends on the measure used for dp. For
uniform spheres, k = 1.5, while more angular particles have higher
values.

9
 10 Nov 2023

Flow of Solids from an Unregulated Orifice

Nedderman (1992) proposed

The flowing density is typically 10% to 20% less

than the static bulk density (Hosseini-Ashrafi &
Tüzün, 1993).

Volumetric and Gravimetric Feeders

•In most process applications, the flow
rate of solids leaving a bin or hopper is
governed by a device that ensures a
constant flow rate on a volume flow or
mass flow basis, and that permits the flow
to be turned off when necessary.
•The design of the feeder is an integral part
of the design of the bin and hopper.

10
 10 Nov 2023

Volumetric and Gravimetric Feeders

• Volumetric feeders can only provide a constant mass
flow rate to a process if the flowing density of the
solids at the hopper discharge remains constant.
When more precise control of mass flow rate is
needed, a gravimetric feeder must be used.
• Gravimetric feeders usually consist of a weighing
device in line with a volumetric feeder so that the
volumetric feeder rate can be adjusted using feedback
from the weighing device. Batch and continuous
weighing devices are used.

Volumetric and Gravimetric Feeders

• For mass flow to occur in the bin, the feeder
shape and opening must allow material to
discharge uniformly across the open area at
the base of the hopper.
• The feeder must also allow flow of solids to be
interrupted and resumed and must prevent the
stationary solids from wicking moisture from
downstream fluid operations.

11
 10 Nov 2023

Volumetric and Gravimetric Feeders

•Belt Feeder
•Screw Feeder
•Table Feeder
•Vibratory Feeder
•Rotary Feeder

BELT FEEDER
• also known as apron feeders
• the base of the hopper section discharges slightly above a
conveyor belt. If the belt is stopped, the solids cannot spill out
and flow ceases.
• The volume flow of solids can be varied by adjusting belt
speed.

12
 10 Nov 2023

SCREW FEEDER
•uses a variable pitch screw is used to move
the solids.

TABLE FEEDER
•the solids discharge onto a rotating table
and are scraped off the table by a
stationary plow.

13
 10 Nov 2023

VIBRATORY FEEDER
• Used for lower solids feed rates that require precise control
feeder can be used.
• the hopper discharges onto a pan that is vibrated at a controlled
speed to give a constant volume flow of solids.
• have a high range of turndown, from 5% to 100% of capacity, but
they can be difficult to operate with fine powders that settle or
deaerate on the pan.

ROTARY FEEDERS
• also known as rotary vane feeders or star feeders.
• used for precise control of volume feed rate from
larger openings.
• the feed rate can be controlled by adjusting the speed
of the rotary valve (star valve).
• useful when feeding into contained systems such as
pneumatic conveyors or fluidized beds.
• prone to jamming when the tolerances between the
vanes and casing are small.

14
 10 Nov 2023

ROTARY FEEDERS

CONVEYING OF SOLIDS
The movement and storage of solids is usually more
expensive than the movement of liquids and gases, which
can be easily pumped down a pipeline. The best
equipment to use to move solids will depend on a number
of factors:

1. Throughput/capacity
2. Length of travel
3. Change in elevation
4. Nature of the solids: size, bulk density, angle of repose,
angle of wall friction, abrasiveness, corrosiveness, wet,
or dry

15
 10 Nov 2023

BELT CONVEYORS
• an endless belt operating between two pulleys with
its load supported on idlers.

BELT CONVEYORS
• They can carry a wide range of materials economically
over long and short distances, either horizontally or at
an appreciable angle, depending on the angle of repose
and angle of wall (belt) friction of the solids.
• The belt material is usually fabric-reinforced rubber or
plastic; segmental metal belts are also used.
• Belts can be specified to withstand abrasive and
corrosive materials.

16
 10 Nov 2023

BELT CONVEYORS
The design, installation, operation, and maintenance of
conveyor belts are covered in the Conveyor Equipment
Manufacturers Association Standard (CEMA, 2007) and
are also addressed by several international (ISO)
standards; see BS EN ISO 21183, BS EN ISO 14890, and
BS EN ISO 15236.

BELT CONVEYORS
• Polymer or rubber belt conveyors are restricted to
running at ambient conditions and cannot handle hot
solids, though metal belts can run hot and are used in
belt dryers.
• The belt width and speed depend on the particle size
and bulk density of the material.
• The lowest cost is obtained by using a narrow belt
running at high speed, but dust formation can limit the
obtainable speed, particularly if the belt is not
covered.

17
 10 Nov 2023

BELT CONVEYORS
• Speeds up to 5 m/s are possible, although 2 to 3 m/s is
most typical.
• The carrying capacity can be determined from the belt
speed, load cross-sectional area, and material bulk
density.
• The load cross-sectional area depends on the angle of
repose of the solids, the depth of filling, and whether
or not the conveyor has side idlers to prevent spillage
at the sides.

BELT CONVEYOR
• The belt may be flat for transporting bagged
material or V-shaped or some other enclosed
shape for moving bulk grains.
• The belt conveyor consists of a belt, drive
mechanism and end pulleys, idlers and loading
and discharge devices

18
 10 Nov 2023

BELT CONVEYOR

BELT CONVEYOR
• Belt conveyors have anti-friction bearing therefore,
these have a high mechanical efficiency.
• Belt can be run at higher speeds, so, large carrying
capacities are possible.
• Compared to other types of horizontal conveying
system, the belt conveyor has high initial cost for short
distances. But for longer distances, the initial cost of
belt conveying system is competitive.

19
 10 Nov 2023

BELT CONVEYOR
• The Table adapted from data of Raymus (1984), gives
the relationships between belt width, maximum lump
size, and load cross-sectional area for a troughed belt
with idlers.
• Load cross-sectional areas for other designs and belt
sizes are given in CEMA (2007).
• Belt conveyors used in mining can be several
kilometers long, but most belt conveyors in the
process industries are shorter than 100 m.

BELT CONVEYOR

20
 10 Nov 2023

BELT CONVEYOR
• The design of belt conveyor system is based on available
space, horizontal conveying length and conveying lift,
characteristics of the material to be conveyed and capacity
requirement.
• the following will be determined to design a belt conveyor:
• belt width
• belt speed
• required horsepower
• maximum belt tension
• breaking strength of the belt
• diameter of the pulleys and idlers and
• quality of belt. (thickness.)

DESIGN GUIDELINES
• The belt speed should be selected to minimize product
spillage or removal of fines due to velocity of the belt
• For transportation of grains, the belt speed should not
increase 3.5 m/s.
• Generally, for grain conveying, belt speed of 2.5 to 2.8
m/s is recommended.
• The selection of belt width will depend upon the
capacity requirement, speed of operation, angle of
inclination of belt conveyors, trough angle and depth.

21
 10 Nov 2023

DESIGN GUIDELINES
Capacity of belt conveyor

where C is the capacity is in m2/hr

A is the cross sectional area in m2
vbelt is belt speed in m/min

DESIGN GUIDELINES
Trough Angle
• A trough angle of 20o is best suited for paddy and most other
grains. Other common trough angles are 30o and 45o.
• Paddy forms a surcharge angle (A) of 20o. Other common
surcharge angle ranges between 5o and 30o.
• Belt incline is limited to 15-17 deg for grain

22
 10 Nov 2023

DESIGN GUIDELINES

Horse power requirement of the belt conveyor

0.48𝐶 + 0.01𝐿
𝐻𝑃 =
100

vbelt is belt speed in m/min

C is the capacity is in t/hr
L is the length of belt, m

DESIGN GUIDELINES

23
 10 Nov 2023

SCREW CONVEYOR
• The screw conveyor consists of a tubular or U-shaped
trough in which a shaft with spiral screw revolves.
• The screw shaft is supported by end and hanger bearings.

SCREW CONVEYOR
• also called worm conveyors.
• used for materials that are free flowing.
• used horizontally or, with some loss of capacity, at an
incline to lift materials.
• less efficient than belt conveyors, due to the friction
between the solids and the flights of the screw and the
trough, but are cheaper and easier to maintain.
• used to convey solids over short distances, and when
some elevation (lift) is required. They can also be used
for delivering a metered flow of solids.

24
 10 Nov 2023

SCREW CONVEYOR
• The rotation of screw pushes the grain along the trough.
• used in grain handling facilities, animal feed industries
and other installations for conveying of products
generally for short distances.
• requires relatively high power and is more susceptible to
wear than other types of conveyors.
• The pitch of a standard screw which is the distance from
the center of one thread to the center of the next thread,
is equal to its diameter.
• For example: 10 cm diameter screw has a pitch of 10 cm.

SCREW CONVEYOR
• As the screw conveyor’s driving mechanism
is required, the initial cost of the conveyor
is lower than any other conveyor with the
same length and capacity.
• The main parts of a screw conveyor are
• drive mechanism
• conveyor casing
• cover inlet and outlet gates,
• bearings
• screw blade and shaft

25
 10 Nov 2023

SCREW CONVEYOR

SCREW CONVEYOR
• The screw conveyor is generally used to move
grains horizontally.
• It can also be used at any angle up to 90o from the
horizontal, but the capacity correspondingly
reduced as per the inclination of conveyance.
• Used to handle finely divided powders, damp,
sticky, heavy viscous materials, hot substances,
chemically active materials, and granular material
of all types
• Half standard pitch are used on incline more than
20°.

26
 10 Nov 2023

DESIGN GUIDELINES

C = capacity, m3/hr
D = screw diameter, in
d = shaft diameter, in
P = pitch diameter, in (~D)
n = rpm

27
 10 Nov 2023

DESIGN GUIDELINES

where, C = conveyor capacity, m3/hr

L = conveyor length, m
W = bulk material weight, kg/m3
F = material factor ( for paddy 0.4)*

If the calculated horsepower is less than 1.0, double the value.

horse power = 1 to 2 multiply the value by 1.5
horse power = 2 to 4 multiply the value by 1.25
horse power = 4 to 5 multiply the value by 1.1
For horsepower values of more the 5, no correction is required.
*Screw Conveyor Bulk Material Table | Engineering Guide (kwsmfg.com)

28
 10 Nov 2023

SCREW CONVEYORS

• can also be operated in an inclined position. In this

case, the material will be conveyed upward. The
capacity of inclined screw conveyor decreases than
the horizontal operation.
• A screw conveyor inclined 15 degrees will carry about
75% of the rated horizontal capacity.
• At an inclination of 25 degrees, it will carry about 50%
of the rated horizontal capacity.

PNEUMATIC CONVEYING
• is used for movement of solids over relatively
short distances.
• generally suitable only for free-flowing particles
in the range 20 μm to 50 mm, as finer dusts tend
to stick to the pipes, while larger particles are
hard to entrain. In pneumatic conveying, the
solids are transported in suspension in a gas.

29
 10 Nov 2023

PNEUMATIC CONVEYING
• the solids may be either dilute phase, with void
fraction typically greater than 95%, or dense
phase, with void fraction as low as 50%. The
velocity of carrier fluid must be large enough to
keep the particles suspended.
• pneumatic conveying can be used for both
horizontal and vertical transport of solids,
including making pipe turns.

PNEUMATIC CONVEYING
• the solids are usually fed from a hopper via a
rotary vane feeder that prevents backflow and are
entrained into the gas flow.
• can also be used under slight vacuum, as a means
of unloading feed tankers or lifting solids into
silos.

30
 10 Nov 2023

PNEUMATIC CONVEYING
• A flexible feed hose attached to the silo is used to suck
up the solids, rather like a domestic vacuum cleaner. A
vacuum compressor is used to pull air out of the silo. A
combination of a cyclone and filter will usually be used
upstream of the vacuum compressor to prevent damage
from particulates.
• Small, portable pneumatic conveyors with flexible hoses
instead of piping are often used for conveying solids over
small distances in the manufacture of specialty
chemicals and pharmaceuticals.

HYDRAULIC CONVEYING
• similar to pneumatic conveying, but uses a liquid
rather than a gas as the carrier fluid.
• The smaller difference in specific gravity between
the particles and carrier fluid makes it easier to
entrain solids, but it is much harder to separate the
solids from the carrier.
• Because pumps are less susceptible to damage by
solids than compressors, hydraulic conveying
systems usually mix the solid and liquid upstream of
the pump and then pump the resulting slurry.

31
 10 Nov 2023

HYDRAULIC CONVEYING

PNEUMATIC AND HYDRAULIC

CONVEYING

32
 10 Nov 2023

BUCKET ELEVATOR

BUCKET ELEVATORS
• The most widely used equipment where a vertical
lift is required
• This consists of buckets fitted to an endless chain or
belt, which passes over a driven roller or sprocket at
the top end.
• can handle a wide range of solids, from heavy lumps
to fine powders, and are suitable for use with wet
solids and slurries.

33
 10 Nov 2023

BUCKET ELEVATORS
• A bucket elevator consists of buckets attached to a
chain or belt that revolves around two pulleys one at top
and the other at bottom.
• The vertical lift of the elevator may range between few
metres to more than 50 m.
• Capacities of bucket elevators may vary from 2 to 100
t/hr.
• Bucket elevators are broadly classified into centrifugal,
positive (gravity), and continuous (direct gravity)

DESIGN GUIDELINES
• The bucket elevator’s capacity mainly depends on
• bucket size,
• conveying speed,
• bucket design and
• spacing the way of loading and unloading the bucket
• characteristic of bulk material
• Belt speed is the first critical factor to consider.
• Bucket elevators with a belt carrier can be used at fairly
high speeds of 2.5 to 4 m/s. The speed of the belt depends
on the head pulley speed.

34
 10 Nov 2023

DESIGN GUIDELINES
• The gravitational discharge occurs with non-adhesive bulk
material elevated at low speed and by means of buckets
mounted closely together.
• With purely centrifugal discharge, complete contents of a
bucket are projected towards the discharge chute.
• Such type of discharge is obtainable with high belt speeds
and elevators is a combination of centrifugal and
gravitational discharge. Part of the bucket contents is
projected by the centrifugal force, the rest flows out by
gravity

DESIGN GUIDELINES
Elevator capacity (m3/h)
= (bucket capacity in m3) x (number of buckets per
meter) x (belt speed in meters per minute) x (60
minutes per hour)

The main parts of a bucket elevator are, (1) elevator

head section, (2) elevator boot section, (3) elevator legs,
(4) belts for bucket elevator and (5) buckets.

35
 10 Nov 2023

DESIGN GUIDELINES

Theoretical Horsepower Requirement

𝐶𝐻𝐹
𝐻𝑃 =
4562
Q = capacity in kg/min
H = lift in meters
F = 1.2 and 1.5 for elevators loaded on the bottom side and upside
respectively.

Actual power is 10-15% higher due to friction, transmission and drive losses

36
 10 Nov 2023

LABORATORY EXERCISE 4

Prepare the following for your processing plant:

1. Design of Storage Facility

2. Design of Material Handling Systems

37